PISTON WITH ASYMMETRIC UPPER COMBUSTION SURFACE AND METHOD OF MANUFACTURE THEREOF

Abstract

A galleryless piston and method of construction provide a piston body forged from a single piece of material having an upper combustion surface extending around a longitudinal center axis along which the piston reciprocates for exposure to a combustion chamber of an internal combustion engine. The upper combustion surface has an asymmetric geometry relative to a center plane extending along the central longitudinal axis in generally perpendicular relation to a pin bore axis.

Claims

1. A galleryless piston for an internal combustion engine, comprising: a monolithic piston body extending along a central longitudinal axis along which said piston reciprocates in a cylinder bore of an internal combustion engine, said piston body having an upper combustion wall forming an upper combustion surface with an annular ring belt region depending from said upper combustion surface for receipt of at least one piston ring; a pair of skirt panels depending from said ring belt region to facilitate guiding the piston within a cylinder bore and having a pair of pin bosses providing a pair of laterally spaced pin bores aligned along a pin bore axis for receipt of a wrist pin; said upper combustion surface having first and second portions, said first portion extending annularly along an outer periphery of said upper wall and said second portion forming a combustion bowl depending from said first portion; said upper combustion wall having an undercrown surface formed on an underside of said combustion bowl directly opposite said second portion of said upper combustion surface, said second portion of said upper combustion surface having an asymmetric geometry relative to a center plane extending along said central longitudinal axis and transversely to said pin bore axis.

2. The piston of claim 1, wherein said undercrown surface has an asymmetric geometry relative to said center plane.

3. The piston of claim 2, wherein said undercrown surface follows a contour of said combustion bowl.

4. The piston of claim 1, wherein said upper combustion wall has a substantially constant thickness.

5. The piston of claim 1, wherein said asymmetric geometry includes a pair of inclined upper combustion surfaces formed on opposite sides of said pin bore axis.

6. The piston of claim 5, wherein said inclined upper combustion surfaces are generally aligned with one another along the direction of a thrust axis extending transversely to said pin bore axis.

7. The piston of claim 5, wherein said inclined upper combustion surfaces extend upwardly from a floor of the combustion bowl to said first portion of said upper combustion surface.

8. The piston of claim 7, wherein said inclined upper combustion surfaces extend circumferentially relative to said central longitudinal axis.

9. The piston of claim 8, wherein said pair of inclined upper combustion surfaces ascends from said floor in one of a clockwise direction or counterclockwise direction relative to said central longitudinal axis.

10. A method of manufacturing a galleryless piston for an internal combustion engine, comprising: forging a monolithic piston body having a central longitudinal axis along which the piston reciprocates in a cylinder bore of an internal combustion engine, and further including forging the monolithic piston body having the following: an upper combustion wall forming an upper crown configured for direct exposure to combustion gases and an undercrown surface opposite the upper crown; a pair of skirt panels depending from the upper combustion wall; a pair of pin bosses having a pair of laterally spaced pin bores aligned along a pin bore axis for receipt of a wrist pin; and forging the upper crown having first and second portions, the first portion extending annularly adjacent an outer periphery of the upper combustion wall and the second portion forming a combustion bowl depending from the first portion, wherein the second portion is forged having an asymmetric geometry relative to a center plane extending along the central longitudinal axis and transversely to the pin bore axis.

11. The method of claim 10, further including forging the undercrown surface to have an asymmetric geometry relative to the center plane.

12. The method of claim 11, further including forging the undercrown surface to follow a contour of the combustion bowl.

13. The method of claim 10, further including forging the upper combustion wall to have a substantially constant thickness.

14. The method of claim 10, further including forging the asymmetric geometry to include at least one inclined upper combustion surface.

15. The method of claim 14, further including forging the at least one inclined upper combustion surface to include a pair of inclined upper combustion surfaces formed on opposite sides of the pin bore axis.

16. The method of claim 15, further including forging the inclined upper combustion surfaces to be generally aligned with one another along the direction of a thrust axis extending transversely to the pin bore axis.

17. The method of claim 14, further including forging the at least one inclined upper combustion surface to extend upwardly from a floor of the combustion bowl to the first portion of the upper combustion surface.

18. The method of claim 17, further including forging the at least one inclined upper combustion surface to extend circumferentially at least partially about the central longitudinal axis.

19. The method of claim 18, further including forging the at least one inclined upper combustion surface to ascend from the floor in one of a clockwise direction or counterclockwise direction relative to the central longitudinal axis.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] These and other aspects, features and advantages of the invention will become more readily appreciated when considered in connection with the following detailed description and accompanying drawings, in which:

[0020] FIG. 1 is a side view of a galleryless piston manufactured in accordance with one aspect of the invention;

[0021] FIG. 2 is a top plan view of the piston of FIG. 1 illustrating an asymmetric combustion bowl in accordance with another aspect of the invention;

[0022] FIG. 3 is a cross-sectional side view taken generally along the line 2-2 of FIG. 2, coinciding with a pin bore axis of the piston of FIG. 1;

[0023] FIG. 4 is a cross-sectional perspective view of the piston of FIG. 1 taken generally along the line 4-4 of FIG. 2; and

[0024] FIG. 5 is a cross-sectional bottom plan view taken generally along the pin bore axis of the galleryless piston of FIG. 1.

DETAILED DESCRIPTION OF PRESENTLY PREFERRED EMBODIMENTS

[0025] Referring in more detail to the drawings, FIGS. 1-5 illustrate views of a galleryless piston 10 constructed in accordance with an example embodiment for reciprocating movement in a cylinder bore or chamber (not shown) of an internal combustion engine, such as a modern, compact, high performance vehicle engine, for example. The piston 10, being “galleryless,” does not have a cooling gallery floor or other cooling gallery features that would tend to suspend oil in a region 14 of the piston crown 16, and thus, not having the added material that would be needed to form a cooling gallery, the piston 10 has a relatively reduced size and weight and operates at a relatively reduced temperature, which contributes to improved thermal efficiency, fuel consumption, and running performance of the engine.

[0026] As shown in the Figures, the piston 10 has a monolithic piston body, referred to hereafter as body 11, forged from a single piece of metal material, such as steel, though it is contemplated that other materials, such as aluminum, titanium, or other structural metal, could be used. Accordingly, the piston 10 does not have a plurality of parts joined together, such as upper and lower parts joined to one another, which is commonplace with pistons having enclosed or partially enclosed cooling galleries bounded or partially bounded by a cooling gallery floor.

[0027] The body 11, being made of steel or another metal, is strong and durable to meet the high performance demands, i.e. increased temperature and compression loads, of modern day high performance internal combustion engines. The steel material used to construct the body can be an alloy, such as the SAE 4140 grade or different, depending on the requirements of the piston 10 in the particular engine application. Due to the piston 10 being galleryless, the weight and compression height of the piston 10 can be greatly reduced relative to a piston having a cooling gallery, thereby allowing an engine in which the piston 10 is deployed to achieve a reduced weight and to be made more compact, thereby allowing the overall outer size of the engine to be reduced. Further yet, even though the piston 10 is galleryless, the piston 10 can be sufficiently cooled during use, due to structural and method of manufacture advances discussed hereafter, to withstand the most severe operating temperatures, thereby owing, at least in part, to the ability of the piston to resist carbon buildup on an undercrown surface 13, thus, further enhancing the performance of the piston 10 and engine.

[0028] The body 11 of the piston 10 has the upper crown or simply crown 16, also referred to as an upper combustion surface 16, extending around a longitudinal center axis A, along which the piston reciprocates, with the upper combustion surface 16 being configured in accordance with one aspect of the invention for optimal exposure to and circulation/mixing of combustion gasses within the combustion bowl 12 and combustion chamber of the engine. The upper combustion surface 16 has first and second portions, with the first portion 17 extending annularly in planar or generally planar form adjacent an outer periphery of the upper combustion surface 16 and the second portion forming the combustion bowl 12 depending from the first portion 17. The combustion bowl 12 is forged to have an asymmetric geometry relative to a center plane of the piston, wherein, as best shown in FIG. 4, the center plane can be a center plane CP-1 that extends along the central longitudinal axis A in generally perpendicular relation to a thrust axis TA and generally along or in parallel relation with a pin bore axis PA, and/or the center plane can be a center plane CP-2 that extends along the central longitudinal axis A and in generally perpendicular relation to the pin bore axis PA and generally along or in parallel relation with the thrust axis TA. Due to the asymmetric geometry of the upper combustion surface 16 and combustion bowl 12 depending therein, certain areas of the region 14 can include more material, in surface area and volume, than other areas to improve performance of the piston 10. For example, areas of the upper combustion surface 16 which are most prone to wear can include more material than other areas which are less prone to wear, such as generally along the region of the thrust axis TA.

[0029] In one example embodiment, as shown in FIGS. 2-4, the upper combustion surface 16 includes an annular outer combustion bowl rim, referred to hereafter as outer rim 18, surrounding the center axis A and combustion bowl 12, with the combustion bowl 12 depending from and extending from the outer rim 18 radially inwardly to the center axis A. The upper combustion surface 16 within the combustion bowl 12 also includes at least one, and shown, by way of example and without limitation, as a pair of features 22 that form the asymmetry of the upper combustion surface 16 and lend to the ability of the piston 10 to attain a reduced size, weight, and increased performance, including withstanding increased temperatures and combustion forces, and further lend to an increased useful life, such as by inhibiting the buildup of deposits on the piston 10. The features 22 are shown, by way of example and without limitation as inclined surfaces (inclined is intended to mean the surfaces extend in oblique relation to a plane extending transversely to the central longitudinal axis A) and/or undulating surfaces (undulating is intended to mean the surfaces can be other than flat or planar), such as inclined ramp-like regions, and referred to hereafter simply as ramps 22, extending upwardly from a floor 20 of the combustion bowl 12 to (into smooth transition with), or generally to (close proximity to) the outer rim 18. The ramps 22 extend over an arcuate path, and are shown as extending circumferentially at least partially about the central longitudinal axis A in smooth (non-stepped) descending fashion from (smooth transition from), or substantially from (slight axial offset from) the outer rim 18 to the floor 20 of the bowl 12, by way of example and without limitation. The ramps 22 provide the upper combustion surface 16 with the asymmetric geometry, such that without the ramps 22, the upper combustion surface would be symmetrical relative to the center planes CP-1, CP-2 and would not likely result in the performance benefits discusses above and further hereafter. It is to be recognized that other configurations of the features 22 than shown can be used to achieve the asymmetric geometry and performance enhancements provided thereby. For example, the piston 10 could include any of the combustion bowl designs disclosed in U.S. Pat. No. 9,243,582, which is incorporated herein by way of reference with regard to the configuration of the combustion bowls disclosed therein. However, unlike the piston of the incorporated '582 patent, the piston 10 according to the present invention is forged from a single piece of material, not welded, and the undercrown surface 13 is forged, not machined. In addition, as discussed above, the piston 10 of the present invention does not include a closed or partially closed cooling gallery.

[0030] As shown in the exemplary embodiment, the piston 10 also includes a ring belt region 24 depending from the upper combustion surface 16 and extending circumferentially along an outer diameter of the piston 10. The ring belt region 24 includes a plurality of lands 26 separated from one another by ring grooves 28. The piston 10 is illustrated having three ring grooves 28, but a piston 10 manufactured in accordance with the invention could alternatively include fewer or more ring grooves 28.

[0031] The piston 10 further includes a pair of pin bosses 30 depending generally from the undercrown surface 13 radially inwardly of the ring belt region 24. The pin bosses 30 provide a pair of laterally spaced pin bores 32 which are vertically spaced from the undercrown surface 13 and coaxially aligned with one another along the pin bore axis PA. The piston 10 also includes a pair of skirt panels 36 depending from the ring belt region 24 and extending diametrically opposite one another along opposite sides of the pin bore axis PA.

[0032] As best shown in FIG. 5, the undercrown surface 13 of the example piston 10 of FIG. 2 is formed on an underside of an upper combustion wall 34 of the crown 16, directly opposite the crown 16 and radially inwardly of the ring belt region 24. For cooling purposes, the undercrown surface 13 is preferably spaced a minimum distance from the combustion bowl 12, though it is recognized that a thickness (t) of the upper combustion wall 34 must be sufficient to withstand combustion forces, and is substantially the surface on the direct opposite side of the upper combustion wall 34 from the combustion bowl 12. Accordingly, the thickness (t) of the upper combustion wall 34 can be optimized to provide a minimum but sufficient generally constant or substantially constant thickness (t) (generally and substantially are intended to mean that slight variances in thickness, as would be recognized by those skilled in the art, are contemplated, such as between about 0-10%, and more preferably between about 0-5%, and more preferably yet between about 0-2% variance in thickness over the generally and substantially constant thickness regions) between the combustion bowl 12 and the undercrown surface 13 in the forging process, thereby enhancing the cooling effectiveness of the upper combustion wall 34 from oil splashing on the undercrown surface 13 during use, while also being able to withstand the high performance combustion forces and minimize the weight of the piston 10. As such, the undercrown surface 13 can be forged having a contoured asymmetrical geometry corresponding to (following) the asymmetric geometry of the upper combustion surface 16, such the undercrown surfaces disclosed in the '582 patent; however, the contour of the undercrown surface 13 is formed to net-shape (finished use shape) in the forging process along with the upper combustion surface 16, unlike in the '582 patent which requires machining. The undercrown surface 13 is considered herein to be the surface that is visible, excluding the pin bores 32 when observing the piston 10 straight on from the bottom, as shown in FIG. 5. The undercrown surface 13 is also openly exposed, as viewed from an underside of the piston 10 and it is not bounded by an enclosed or partially enclosed cooling gallery, or any other features tending to retain oil or a cooling fluid near the undercrown surface 13. The undercrown surface 13 can be formed having various configurations, other than those disclosed in the Figures of the present application, as similarly noted for the asymmetrical upper combustion surface.

[0033] According to the example embodiment, the undercrown surface 13 of the piston 10 has greater a total surface area (3-dimensional area following the contour of the surface) and a greater projected surface area (2-dimensional area, planar, as seen in plan view) than comparative pistons having a closed or partially closed cooling gallery. This open region along the underside of the piston 10 provides direct access for oil to be splashed or sprayed from within the crankcase directly onto the “as forged” asymmetrical undercrown surface 13, thereby allowing the entire undercrown surface 13 to be splashed directly by oil from within the crankcase, while also allowing the oil to freely splash about the wrist pin (not shown), and further, significantly reduce the weight of the piston 10. Accordingly, although not having a typical closed or partially closed cooling gallery, the generally open configuration and reduced, generally constant wall thickness (t) of the upper combustion wall 34, other than directly above the pin bosses 30, of the galleryless piston 10 allows optimal cooling of the undercrown surface 13 and lubrication to the wrist pin joint within the pin bores 32, while at the same time greatly reducing oil residence time (the time in which a volume of oil remains on a surface) on the surfaces near the combustion bowl 12. The reduced residence time can reduce unwanted build-up of coked oil, such as can occur in pistons having a closed or substantially closed cooling gallery. As such, the piston 10 can remain “clean” over extended use, thereby allowing it to remain substantially free of coke build-up, thereby maintaining maximum cooling efficiency.

[0034] The undercrown surface 13 of the piston 10 shown in FIGS. 4 and 5 is provided by several regions, including an inner undercrown region 38 and outer pockets 40. A first portion of the undercrown surface 13 located at and immediately adjacent the center axis A is provided by an inner undercrown region 38. The inner undercrown region 38 extends between and is surrounded by the pin bosses 30, skirt panels 36, and struts 42. The 2-dimensional and 3-dimensional surface area of the undercrown surface 13 provided by the inner undercrown region 38 is typically maximized by its asymmetry, following the asymmetry of the combustion bowl 12, so that cooling caused by oil splashing or being sprayed upwardly from the crankcase against the exposed inner undercrown region 38 can be enhanced, thereby lending to exceptional cooling of the piston 10. In the example embodiment illustrated, the inner undercrown region 38 of the undercrown surface 13 is concave, when viewed from the bottom, such that oil can be channeled during reciprocation of the piston 10 from one side of the piston 10 to the opposite side of the piston 10, thereby acting to further enhance cooling of the piston 10.

[0035] A second region of the undercrown surface 13 is provided by the outer pockets 40 which are located radially outwardly of the pin bosses 30. Each outer pocket 40 is surrounded by one of the pin bosses 30, portions of the struts 42 that connect the skirt panels 36 to the pin bosses 30, and a portion of the ring belt region 24.

[0036] Another aspect of the invention provides a method of manufacturing the galleryless piston 10 with the asymmetric combustion bowl 12. The body portion of the piston 10 is formed by forging a single piece of steel material. The forging step includes forming the upper combustion wall 34 to include the upper combustion surface 16 having the asymmetric geometry in the select areas of the combustion bowl 12. In other words, the piston 10 is preformed, without need of subsequent machining, with the asymmetric geometry formed within the combustion bowl 12 in the forging process. The forging step can also include forming the other features of the piston 10 including the ring belt region 24, pin bosses 30, skirt panels 36, inner undercrown region 38, and outer pockets 40, as described above. The forging step is simpler and more efficient than welding two pieces of material. After forging the single piece of steel material, the method typically includes finish machining the ring belt region 24, pin bosses 30, and skirt panels 36. The method can optionally include finish machining the combustion bowl 12, but preferably the combustion bowl 12 is completely formed to net shape during the forging step and no finish machining is required.

[0037] The single piece forged piston 10 with the asymmetric geometry on the upper combustion surface 16 provides advantages over welded pistons. It is typically important to align the asymmetric geometry provided by the undulating/inclined regions 22 on the upper combustion surface 16 in a specific location relative to the pin bore axis 34 and central planes CP-1, CP-2. The specific location varies depending on the design of the engine in which the piston 10 is used. If the piston were to be formed by welding two pieces together, it would be difficult at best, and more likely impossible to align an asymmetric geometry of the upper combustion surface in the desired location relative to a center plane. However, when the piston 10 is forged from a single piece of material in accordance with the present disclosure, it is not only possible, but relatively easy to align the asymmetric geometry of the features on the upper combustion surface in the correct location relative to the center planes CP-1, CP-2. Thus, manufacturing time and costs can be greatly reduced when the asymmetric geometry is provided on the single piece forged piston 10 in comparison to a welded piston, if even possible. In addition to the time and cost savings offered by the disclosure herein, the proper alignment of the asymmetric geometry attained thereby is believed also contribute significantly to weight and size reductions of an engine and to the improved performance of the engine.

[0038] Many modifications and variations of the present invention are possible in light of the above teachings and may be practiced otherwise than as specifically described while remaining within the scope of the claims. It is contemplated that all features of all claims and of all embodiments can be combined with each other, so long as such combinations would not contradict one another.